Power module

ABSTRACT

A power converter module includes a ground terminal, an input voltage terminal configured to receive a raw input voltage, and an interconnection terminal configured to provide a regulated output voltage to a load such as a SOC or SIP system to be powered. A voltage regulator is connected to the ground terminal and the input voltage terminal. An inductor has an inductor output connected to the interconnection terminal.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. patent application Ser. No.15/901,578, filed Feb. 21, 2018, and titled “Power Module”, now U.S.Pat. No. 11,245,329, which claims the benefit of U.S. ProvisionalApplication No. 62/565,578, filed Sep. 29, 2017, and titled “PowerModule,” the disclosure of each of which is hereby incorporated hereinby reference in its entirety.

BACKGROUND

A voltage regulator converts an input voltage to a different outputvoltage. An example of a typical application is a battery poweredelectronic device such as a portable computer. In an example such asthis, a voltage regulator is required to provide a predetermined andconstant output voltage to a load from an often fluctuating inputvoltage source, the battery.

Depending on several factors, such as the arrangement of power regulatorcomponents relative to components of the powered system, known powerregulation devices have shortfalls, such as coupling and heatingeffects, parasitic capacitance at the output stage, interconnection andintegration limitations, etc.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isnoted that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIG. 1 is a block diagram illustrating aspects of a modular power systemin accordance with some embodiments.

FIG. 2 is a block diagram illustrating further aspects of the modularpower system in accordance with some embodiments.

FIG. 3 is a block diagram illustrating further aspects of the modularpower system in accordance with some embodiments.

FIG. 4 is a block diagram illustrating aspects of a voltage regulator ofthe modular power system shown in FIGS. 1-3 in accordance with someembodiments.

FIG. 5 is a top view illustrating further aspects of the modular powersystem in accordance with some embodiments.

FIG. 6 is a section view illustrating further aspects of the modularpower system in accordance with some embodiments.

FIG. 7 is a top view illustrating further aspects of the modular powersystem in accordance with some embodiments.

FIG. 8 is a block diagram illustrating multiple interconnected powermodules of the modular power system in accordance with some embodiments.

FIG. 9 is a block diagram illustrating a single phase power modulesystem in accordance with some embodiments.

FIG. 10 is a block diagram illustrating a single-ended, side-by-sidepower module system in accordance with some embodiments.

FIG. 11 is a block diagram illustrating a single-ended, end-to-end powermodule system in accordance with some embodiments.

FIG. 12 is a block diagram illustrating a double-ended, side-by-sidepower module system in accordance with some embodiments.

FIG. 13 is a block diagram illustrating a double-ended, end-to-end powermodule system in accordance with some embodiments.

FIG. 14 is a process flow diagram illustrating aspects of a modularpower method in accordance with some embodiments.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the provided subjectmatter. Specific examples of components and arrangements are describedbelow to simplify the present disclosure. These are, of course, merelyexamples and are not intended to be limiting. For example, the formationof a first feature over or on a second feature in the description thatfollows may include embodiments in which the first and second featuresare formed in direct contact, and may also include embodiments in whichadditional features may be formed between the first and second features,such that the first and second features may not be in direct contact. Inaddition, the present disclosure may repeat reference numerals and/orletters in the various examples. This repetition is for the purpose ofsimplicity and clarity and does not in itself dictate a relationshipbetween the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The apparatus may be otherwise oriented (rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly.

Power management is a necessary function in a variety of integratedcircuit applications. A typical integrated circuit may include a varietyof systems formed by a large number of interconnected components formedon a semiconductor die, and power requirements for such integratedsystems can vary widely.

Power converters are used to provide the desired power for a load. Abuck converter, for example, converts an input voltage to a lower outputvoltage. A synchronous buck converter includes a pair of switchescoupled in series across the input voltage source. One switch is coupledto the voltage source and the other switch is connected to ground. Anoutput filter typically including an inductor and a capacitor isconnected to a junction formed by the pair of switches for providing theoutput voltage to the load. A controller drives the switches to connectthe output filter to the voltage supply or to ground to maintain theoutput voltage at a predetermined level.

Depending on several factors, such as the arrangement of power regulatorcomponents relative to components of the powered system, known powerregulation devices have shortfalls, such as coupling and heatingeffects, parasitic capacitance at the output stage, interconnection andintegration limitations, etc.

FIG. 1 illustrates aspects of a modular power conversion system inaccordance with disclosed examples. The power conversion system 10includes one or more pre-characterized power modules 100 that areconnected to a system 102 powered by the power modules 100. A controller104 (which could be a component of the power modules 100 in someexamples) receives feedback from the powered system 102 and controls thepower modules 100 so as to output the desired power characteristics.

The powered system 102 could be a system on a chip (SOC) in which thevarious system components are integrated on a common substrate. In otherexamples, the powered system 102 is a system in a package (SIP), wheredifferent portions of the system 102 are fabricated on a number ofsubstrates and assembled into a package. In some implementations, thepower modules 100 are all fabricated on a common substrate, and could beintegrated with the system 102 as part of the SOC or SIP.

FIGS. 2 and 3 illustrate further aspects of examples of the system 10.In the embodiments illustrated in FIGS. 2 and 3 , the power modules 100each include a ground terminal 110, an input voltage terminal 112configured to receive a raw input voltage V_(DD-raw), and aninterconnection terminal 140 that provides a regulated output voltageV_(reg) to a load, which is the powered system 102 in the illustratedexamples. The power modules 100 additionally include a power stage, orvoltage regulator 120 that is connected to the ground terminal 110 andthe input voltage terminal 112, as well as an inductor 130 that has aninductor output connected to the interconnection terminal 140. In theillustrated examples, the ground terminal 110 is a global groundterminal, in that the ground of the voltage regulator 120 and the system102 may be shorted together globally. In some examples, the voltageregulator 120 system 102 ground pins may be separated, depending on theparticular SOC or SIP structures.

The voltage regulator 120 could comprise, for example, a buck converter.Aspects of an example buck converter are shown in FIG. 4 . The examplevoltage regulator 120 of FIG. 4 includes first and second, or upper andlower, switches 121, 122 coupled in series between the input voltageterminal 112 and the ground terminal 110, with the high side switch 121coupled to receive the input voltage V_(DD-raw) and the low side switch122 connected to ground. In some embodiments, the high side switch 121comprises a PMOS transistor, while the low side switch comprises an NMOStransistor.

An output filter 124 is connected to a junction formed by the upper andlower switches 121, 122 to provide the output voltage V_(reg) to thesystem 102. The controller 104 drives the switches to connect the outputfilter 124 to the input voltage V_(DD-raw) or to ground to maintain theoutput voltage V_(reg) at a predetermined level. More specifically, thecontroller 104 drives a PWM signal to achieve the desired output voltagelevel, varying the duty cycle of the PWM signal so as to operate theswitches 121, 122 to connect and disconnect the output to and from theinput voltage source.

The filter 124 includes the inductor 130, as well as a capacitor 150. Inthe examples of FIGS. 2 and 3 , the capacitor is located externally tothe power module 100, and may be formed as a component of the system 102or external thereto. In other implementations, the capacitor 150 may beintegrated with the power module 100.

In some examples, the common controller 104 or portions thereof areincluded in the power module 100, while in other examples the 104 isexternal to the power module 100. For instance, for a multiphase powermodule (multiple buck converters connected in parallel) the timing ofeach phase is offset. In such implementations, it may be desirable tointegrate at least a common portion of the controller 106 as part ofpower module 100. For a specific single phase voltage regulatorimplementation, one controller 106 could control single voltageregulators 120.

In some embodiments, the voltage regulator 120, inductor 130, andcontroller 104 are arranged on a common substrate 106. Moreover, FIG. 2illustrates an example system 10 a in which components of the powermodule 100 are arranged on a common substrate 106, while the poweredsystem 102 is separate therefrom and could be an SIP device. In FIG. 3 ,the power module 100 and system 102 are all provided on a commonsubstrate 106 and the system 10 b could thus be an SOC device.

As noted in conjunction with FIG. 4 , the output filter 124 typicallyincludes the inductor 130 and a capacitor 150. In certain examples, theinductor is included as a component of the power module 100, while thecapacitor 150 is formed separately therefrom to be close to the poweredsystem 102. In some known power systems the inductors 130 are integratedwith the system 102. Such arrangements can result in undesired effectson the voltage regulator 120 and/or the powered system 102, such asunintended coupling and heating from the magnetic effects of theinductor, limited interconnection space by the inductor, reducedefficiency, etc. Such effects must be compensated for with each designedsystem.

In some examples disclosed herein, the voltage regulator 120 andinductor 130 are provided together as a module 100, and in someimplementations are formed on a common substrate. This allowscharacterizing the module 100 to avoid such undesired effects on thevoltage regulator 120 and the powered system 102. Further, the powermodules 100 may be constructed so as to output a known, predeterminedpower level, such as 0.5 amps per module 100. Thus, multiple modules 100may be interconnected in parallel to provide the loading requirements ofthe system 102.

FIG. 5 is a top view, and FIG. 6 is a cross section end view,illustrating aspects of a layout of the power modules 100. In theexample of FIGS. 5 and 6 , the high side and low side switches 121, 122of the voltage regulator 120 are positioned directly over a top side 160of the inductors 130 (opposite the bottom side 161 of the inductor 130).This “stacked” arrangement in which the voltage regulator 120 andinductor 130 are stacked on the substrate 106 facilitates a larger powerdensity. Further, positioning the inductors 130 and components of thevoltage regulator 120 separate from the system 102 and capacitors 150helps reduce magnetic coupling to the system 102, among other things. Asshown in FIG. 6 , the high side and low side switches 121, 122 of thevoltage regulator 120 are further positioned adjacent lateral sides 164,165 of the inductor 130, while the voltage input 112 and ground 110terminals are situated at the bottom side 161 adjacent the lateral sides164, 165 of the inductors 130. In this manner, the voltage terminals 112and ground terminals 110 pf the illustrated example are interleaved withthe inductors 130 outside the inductor 130 region, which reducesparasitic losses.

Moreover, the illustrated module 100 includes two inductors 130 andvoltage regulators 120. The illustrated inductors 130 include aferromagnetic core 132, with a conductive winding 134 thereabout. Insome embodiments, the two inductors 130 shown in FIG. 5 may have acommon core 132, with windings 134 situated 180° out of phase with oneanother as indicated by the arrows 136 labeled Vcoil0 and Vcoil180.Thus, the current flow from the inductor output is shown by arrows 138to the interconnect terminals 140 (providing the regulated outputvoltage V_(reg)) situated at the end sides 162, 163 of the inductors130.

FIG. 7 illustrates another example in which the power module 100includes several voltage regulators 120 and inductors 130. As shown inFIGS. 5 and 6 , the interconnect terminal 140 for providing the outputvoltage V_(reg) to the load (e.g. system 102) is provided at the endsides 162, 163 of the inductors 130. The input voltage and groundterminals 112, 110 are positioned on the lateral sides 164, 165 of theinductors 130. In some examples, all of the voltage regulators 120 andinductors 130 are provided on a common substrate, and the power modules100 are pre-characterized so as to minimize interference with thepowered system 102, and to output a predetermined current level.

FIG. 8 is a block diagram conceptually illustrating an arrangement ofmultiple interconnected power modules 100. Each of the power modules 100is connected to the input terminal 112 to receive the raw input voltageV_(DD-raw), and also connects to the interconnect terminal 140 to outputthe regulated voltage V_(reg) to the powered system 102, which as notedpreviously could be configured either as an SOC or SIP. The filtercapacitors 150 are discrete from the power modules 100 in theillustrated example. As mentioned previously, each of the power modules100 are configured so as to output a current level determined byrequirements of the powered system 102. By connecting multiple powermodules together in parallel, the desired total current level can beachieved for the system 102 to be powered.

In some examples, all of the power modules 100 are provided on a commonsubstrate. In other implementations, the power modules 100 are arrangedon individual substrates. In either situation, the power modules 100 arepre-characterized so as to minimize interference with the powered system102, and to output a predetermined current level. Thus, several of thepower modules 100 may be interconnected to achieve the desired currentoutput and power characteristics.

FIGS. 9-13 illustrate examples of various power module arrangements. Thepower modules 100 can include different configurations so as to provideflexible and compact power systems meeting SOC or SIP physicaldimensions and needs of the powered systems 102. For instance, FIG. 9shows a simple single phase power module system 11 that includes acontroller 104 and a single power module 100 with a voltage regulator120 and inductor 130. FIG. 10 illustrates an N-phase (N is a positiveinteger) single-ended, side-by-side power module system 12 that includesa common controller 104 and with N power modules 100. The power modules100 are arranged in a side-by-side fashion on the substrate 106, withthe controller 104 at one end of the power system 12. FIG. 11illustrates an N-phase single-ended, end-to-end power module system 13that includes a common controller 104 with N/2 power modules 100. Eachof the power modules 100 includes two power modules 120 and inductors130 arranged end-to-end as described in conjunction with FIG. 5 . FIG.12 illustrates an N-phase double-ended, side-by-side power module system14 that includes a common controller 104 with N power modules 100positioned on either side of the controller 104. Each of the powermodules 100 are arranged in a side-by-side fashion on the substrate 106.FIG. 13 illustrates an N-phase double-ended, end-to-end power modulesystem 15 that includes a common controller 104 with N/2 power modules100 positioned on either side of the controller 104. Each of the powermodules 100 includes two power modules 120 and inductors 130 arrangedend-to-end as described in conjunction with FIG. 5 .

FIG. 14 is a flow diagram illustrating an example of a modular powermethod 200 in accordance with further aspects of the disclosure. Inblock 210, a plurality of power modules are provided, such as the powermodules 100 described herein. Thus, each of the power modules 100 isconfigured to output a predetermined current level and includes avoltage regulator 120 connected to ground terminal 110 and an inputvoltage terminal 112. The power modules 100 further include an inductor130 having an inductor output that is connected to an interconnectionterminal. Each of the power modules 100 are characterized to output apredetermined current level. In block 212, power requirements for asystem to be powered are determined, and in block 214 a number of thepower modules required to meet the determined power requirements isdetermined. The determined number of the power modules areinterconnected together in block 216, and the interconnected powermodules are connected to the system to be powered in block 218.

Disclosed embodiments include a power converter module that includes asubstrate, a ground terminal, an input voltage terminal configured toreceive a raw input voltage, and an interconnection terminal configuredto provide a regulated output voltage to a load such as a SOC or SIPsystem to be powered. A voltage regulator is arranged on the substrateand is connected to the ground terminal and the input voltage terminal.An inductor is also arranged on the substrate and has an inductor outputconnected to the interconnection terminal.

In accordance with further disclosed embodiments, a modular power systemincludes a ground terminal, an input voltage terminal configured toreceive a raw input voltage, and an interconnection terminal. Aplurality of power modules each have a voltage regulator connected tothe ground terminal and the input voltage terminal, and an inductorhaving an inductor output connected to the interconnection terminal.Each of the power modules is characterized to output a predeterminedcurrent level.

In accordance with still further disclosed embodiments, a modular powermethod includes providing a plurality of power modules that each areconfigured to output a predetermined current level. The power moduleseach have a voltage regulator and are connected to a ground terminal andan input voltage terminal. The power modules each also have an inductorwith an inductor output connected to an interconnection terminal. Eachof the power modules are characterized to output a predetermined currentlevel. Power requirements for a system to be powered are determined, anda number of power modules required to meet the determined powerrequirements is further determined. The determined number of the powermodules are then interconnected together, and the interconnected powermodules are connected to the system to be powered.

The foregoing outlines features of several embodiments so that thoseskilled in the art may better understand the aspects of the presentdisclosure. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

What is claimed is:
 1. A method for providing power to a system, themethod comprising: providing a plurality of power modules, each of theplurality of power modules configured to output a predetermined currentlevel, wherein each of the plurality of power modules comprises: aninput voltage terminal configured to receive a raw input voltage and aground terminal; a voltage regulator connected to the ground terminaland the input voltage terminal, wherein the voltage regulator comprisesa first switch and a second switch; an inductor having an inductoroutput connected to an interconnection terminal; wherein each of thefirst switch and the second switch of the voltage regulator are stackeddirectly over a top side of the inductor such that the inductor ispositioned directly between the voltage regulator and a substrate,wherein the inductor is stacked directly over the substrate, wherein thefirst switch of the voltage regulator is positioned above a firstlateral side of the inductor and the second switch of the voltageregulator is positioned above a second lateral side opposite the firstlateral side of the inductor, wherein the ground terminal is positionedadjacent the second lateral side, and wherein the input voltage terminalis positioned adjacent the first lateral side of the inductor;determining power requirements for the system to be powered; determininga number of the plurality of power modules required to meet thedetermined power requirements; interconnecting the number of theplurality of power modules together; and connecting the interconnectedplurality of power modules to the system to be powered.
 2. The method ofclaim 1, wherein each of the plurality of power modules are formed on acommon substrate.
 3. The method of claim 1, wherein each of theplurality of power modules are formed on respective substrates.
 4. Themethod of claim 1, wherein the plurality of power modules and the systemto be powered are formed on a common substrate.
 5. The method of claim1, wherein the plurality of power modules and the system to be poweredare formed on respective substrates.
 6. The method of claim 1, whereinthe plurality of power modules are connected in parallel.
 7. The methodof claim 1, wherein the inductor includes a magnetic core.
 8. The methodof claim 1, wherein a first power module comprises a first inductor anda second power module comprises a second inductor, wherein the firstinductor includes a magnetic core with a first conductive windingthereabout, and wherein the second inductor includes the magnetic corewith a second conductive winding.
 9. The method of claim 8, wherein thesecond conductive winding is 180° out of phase with the first conductivewinding.
 10. A system comprising: a first power module comprising: afirst substrate, a first inductor stacked over the first substrate,wherein the first inductor comprises a top side opposite a bottom side,a ground terminal, an input voltage terminal, a first voltage regulatorcomprising a first switch and a second switch, wherein the first voltageregulator is stacked over the top side of the first inductor such thatthe first inductor is positioned directly between the first voltageregulator and the first substrate, wherein the first switch of the firstvoltage regulator is positioned over a first lateral side of the firstinductor, wherein the second switch of the first voltage regulator ispositioned over a second lateral side opposite the first lateral side ofthe first inductor, wherein the ground terminal is positioned adjacentto the second lateral side, and wherein the input voltage terminal ispositioned adjacent to the first lateral side of the first inductor; anda second power module connected to the first power module in parallel,wherein the second power module comprises: a second substrate, a secondinductor stacked over the second substrate, wherein the second inductorcomprises a top side opposite a bottom side, and a second voltageregulator comprising a first switch and a second switch, wherein thesecond voltage regulator is stacked over the top side of the secondinductor such that the second inductor is positioned directly betweenthe second voltage regulator and the second substrate, wherein the firstswitch of the second voltage regulator is positioned over a firstlateral side of the second inductor, and wherein the second switch ofthe second voltage regulator is positioned over a second lateral sideopposite the first lateral side of the second inductor.
 11. The systemof claim 10, wherein the first voltage regulator is connected to theground terminal and the input voltage terminal.
 12. The system of claim10, wherein the second voltage regulator is connected to the groundterminal and the input voltage terminal.
 13. The system of claim 10,wherein the first substrate and the second substrate are a commonsubstrate.
 14. The system of claim 10, wherein the first inductorcomprises a common core and a first winding around the common core,wherein the second inductor comprises a second winding around the commoncore, and wherein the second winding is 180° out of phase with the firstwinding.
 15. The system of claim 14, wherein the common core comprises amagnetic core.
 16. A system for providing a power, the system comprisinga plurality of power modules, each of the plurality of power modulesconfigured to output a predetermined current level, wherein each of theplurality of power modules comprises: a substrate; a ground terminal; aninput voltage terminal; a plurality of inductors stacked over thesubstrate, the plurality of inductors comprising: a first inductorcomprising a common core and a first winding around the common core, anda second inductor comprising a second winding around the common core,wherein the second winding is 180° out of phase with the first winding;and a voltage regulator comprising a first switch and a second switch,wherein the voltage regulator is stacked over a top side of theplurality of inductors such that the plurality of inductors arepositioned directly between the voltage regulator and the substrate,wherein the first switch of the voltage regulator is positioned over afirst lateral side of the plurality of inductors, wherein the secondswitch of the voltage regulator is positioned over a second lateral sideopposite the first lateral side of the plurality of inductors, whereinthe ground terminal is positioned adjacent the second lateral side ofthe plurality of inductors, and wherein the input voltage terminal ispositioned adjacent the first lateral side of the plurality ofinductors.
 17. The system of claim 16, wherein the common core comprisesa magnetic core.
 18. The system of claim 16, wherein the voltageregulator is connected to the ground terminal and the input voltageterminal.
 19. The system of claim 16, further comprising aninterconnection terminal configured to provide a regulated outputvoltage to a load.
 20. The system of claim 16, wherein the secondconductive winding is 180° out of phase with the first conductivewinding.